Systems and methods of identifying and manipulating objects

ABSTRACT

Systems and methods of identifying and manipulating objects are disclosed. One system disclosed comprises a light source adapted to emit a collimated light beam onto a contoured surface, a sensor adapted to view a profile of the contoured surface illuminated by the collimated light beam, a processor in communication with the sensor, and a controller in communication with the processor. The controller may be adapted to generate a signal based on an attribute of a predefined profile.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and is a continuation of U.S.application Ser. No. 11/106,224, filed on Apr. 14, 2005 now U.S. Pat.No. 7,640,073, now allowed, which is assigned to the assignee of thepresent application, and which is incorporated in its entirety herein byreference.

FIELD OF INVENTION

The present invention relates to systems and methods of identifying andmanipulating objects, and more particularly identifying and manipulatingobjects having a contoured surface.

BACKGROUND

Fiberboard door skins can be manufactured by pressing wood composites,along with resins, glues, and other substances, into thin layers, whichthen can be laminated or adhered to a core, frame or other support tosimulate a solid, natural wood door. Fiberboard door skins have theadvantages of being economical, not easily damaged, durable over time,and light-weight.

Fiberboard door skins further provide an efficient way to incorporatevarious aesthetically-pleasing patterns into the faces of a door withoutrequiring intricate routing and other labor-intensive woodworkingmethods. One difficulty with pressing door skins, however, is that theedges of the pressed door skins generally are rough and non-uniform.These edges must be trimmed to precise dimensions with respect to anembossed profile before coupling a door skin to the door frame.

A current method of trimming door skins to the desired size involvesaligning one of the uneven edges with a physical guide, edge, or plateand cutting the door skin at a predetermined or measured distance fromthe guide. This method can result in trimmed door skins that aredimensionally out of tolerance or profiles that are skewed. An imprecisecut may result in an assembled door having noticeably overlapping edgesand an unfinished appearance. Such doors often must be discarded, whichultimately may result in increased production costs.

Thus, there is a need for improved systems and methods of identifyingand manipulating objects such as door skins.

SUMMARY OF THE INVENTION

Embodiments of the present invention comprise systems and methods ofidentifying and manipulating objects. The present invention may beembodied in a variety of ways.

One embodiment of the present invention may comprise a system having alight source adapted to emit a collimated light beam onto the contouredsurface of an object. The light beam may be adapted to illuminate aprofile, e.g., a collection of rises and declines, of the contouredsurface. The system may further comprise a sensor adapted to detect theilluminated profile of the contoured surface. The sensor may be adaptedto generate a first signal based at least in part on the illuminatedprofile.

The system may further comprise a processor in operative communicationwith the sensor. The processor may be adapted to receive the firstsignal from the sensor and compare the first signal with a secondsignal. The second signal may be associated with a predefined profile.The processor may be adapted to generate a third signal based on acomparison of the first and second signals.

The system may further comprise a controller in operative communicationwith the processor. The controller may be adapted to receive the thirdsignal and generate a motion control signal in response to the thirdsignal. The motion control signal may be based on an attribute of thepredefined profile.

The present invention may be better understood by reference to thedescription and figures that follow. It is to be understood that theinvention is not limited in its application to the specific details asset forth in the following description and figures. The invention iscapable of other embodiments and of being practiced or carried out invarious ways.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention are better understood when the following Detailed Descriptionis read with reference to the accompanying drawings, wherein:

FIG. 1 shows a schematic representation of a system in accordance withan embodiment of the present invention.

FIG. 2 shows another schematic representation of the system of FIG. 1.

FIG. 3 shows an elevation view of the schematic representation of thesystem of FIG. 1.

FIG. 4 shows a profile of a contoured surface of a door skin shown inFIG. 1.

FIG. 5 shows a block diagram of a method in accordance with anembodiment of the present invention.

FIG. 6 shows a block diagram of a method in accordance with anotherembodiment of the present invention.

DETAILED DESCRIPTION

Embodiments of the present invention comprise systems and methods ofidentifying and manipulating objects, including those having a contouredsurface, such as a door skin with raised or recessed panels. Examples ofother suitable objects include solid doors, cabinet doors, cabinetpanels, drawer facades, baseboards, decorative molding, or any otherobject that has a patterned, contoured, or irregular surface.

A fiberboard door skin is a sheet or mat that can be assembled with adoor frame comprising rails and stiles to form an assembled door. A doorskin may comprise, for example, a nominal caliper ranging between about0.100 inch and about 0.130 inch molded product using a dry processfiberboard mat initially about two inches thick.

A fiberboard door skin may have one or more patterns of raised andrecessed areas. When the door skin emerges from a press, its edges areoften irregular, whereas the decorative pattern is generally consistentand well-formed.

According to an embodiment of the present invention, contours orpatterns formed on objects, such as door skins, are identified and theobject manipulated based at least in part on attributes associated witha specific, predefined contour or pattern. The manipulation can includecutting a door skin to desired dimensions. The present inventionutilizes the uniformity and repeatability of the contours or patterns tomake consistent manipulations of door skins having similar patterns,thus eliminating or reducing the need to rely on positioning the doorskin against a fixed point or making physical measurements in certainembodiments.

Referring now to FIGS. 1-3, an embodiment of a system 10 according tothe present invention is shown. The system 10 comprises a conveyor 70,an emitter 20, such as a light source, and a first sensor 40 and asecond sensor 80 disposed in communication with a processor 50. As willbe described below in further detail, the first sensor 40 may comprise acamera. The system 10 also comprises a controller 60 disposed incommunication with the processor 50 and cutting means 90. The door skin24 may be positioned on a conveyor 70 adapted to move the door skin 24through a plurality of stations. One of the stations, for example, maybe directly under the light source 20, and another station may be at thecutting means 90.

In one embodiment, the system 10 may identify a door skin 24 bydetecting a profile (shown in FIG. 4) of a contoured surface of one ofmore panels 25 of the door skin 24, comparing the profile with apredefined profile (e.g., a target profile), and generating instructionsfor manipulating the door skin 24, such as cutting or trimming the doorskin 24.

The door skin 24 comprises a first surface 28 a and a second surface 28b substantially parallel to the first surface 28 a. The first and secondsurfaces 28 a, 28 b are substantially planar. Generally, a perpendiculardistance between the first surface 28 a and the second surface 28 b isbetween about 0.100 inches and 0.130 inches. In one embodiment, theperpendicular distance between the first surface 28 a and the secondsurface 28 b is between about 0.110 inches and 0.120 inches. The doorskin 24 may have a density in a range between about 50 pounds per cubicfoot (pcf) and 70 pcf. Other suitable densities for the door skin 24 maybe used.

The door skin 24 comprises six molded panels 25. The panels 25 may bedisposed in a plane above and substantially parallel to a plane formedby the first surface 28 a. The door skin 24 comprises six moldeddepressions 26 surrounding the six panels 25. Each of the plurality ofdepressions 26 is surrounded by the first surface 28 a. Alternatively,other suitable configurations may be used.

A plurality of edges 27 a-d form a perimeter about the first and secondsurfaces 28 a, 28 b of the door skin 24. The edges 27 a-d are irregularand non-uniform as a result of the process of manufacturing the doorskin 24, as described above. The extent of the irregularity of the edges27 a-d has been exaggerated to facilitate understanding of the presentinvention.

Desired edges 29 a-d are shown in hidden lines. The edges 29 a-d aresubstantially uniform and straight. Edges 29 a and 29 c aresubstantially parallel to one another, as are edges 29 b and 29 d. Edges29 a and 29 c are substantially perpendicular to edges 29 b and 29 d. Aswill be described in further detail below, the door skin 24 will betrimmed or cut such that the edges 27 a-d will be removed and thedesired edges 29 a-d will form the perimeter of the first and secondsurfaces 28 a, 28 b of the door skin 24.

The light source 20 is adapted to emit a collimated light beam 22 ontothe first surface 28 a of the door skin 24. In one embodiment, thecollimated light beam 22 may comprise a laser. Other suitable collimatedsources of light may be used, such as linear and multidimensionalcollimator arrays. In another embodiment, other sources of energy may beemitted onto the door skin, such as for example, infrared energy.

The collimated light beam 22 is projected onto a portion of the doorskin 24 on which one or more of the molded panels 25 are formed. Thelight source 20 is positioned at a first distance from the first surface28 a of the door skin 24. In one embodiment, the first distance may befixed. Alternatively, the first distance may be variable and adjusted asdesired. The first distance may include distances between two and fourfeet above the first surface 28 a. Other distances may be suitabledepending on the intensity of the light beam 22 and the sensitivity ofthe camera 40.

For example, if the light source 20 is positioned too closely to thefirst surface 28 a, the lens that collimates the light beam 22 maydisperse the light beam 22 too severely, resulting in a fuzzy reflectionof the light beam 22. Conversely, if the light source 20 is positionedtoo far from the first surface 28 a, the light source 20 may not emit alight beam 22 intense enough to clearly reflect off of the first surface28 a.

The light source 20 is aimed to emit the collimated light beam 22 in adirection substantially perpendicular to the first surface 28 a of thedoor skin 24. The light source 20 can be positioned elsewhere, forexample to the side of the door skin 24, emitting a collimated lightbeam 22 obliquely with respect to the first surface 28 a of the doorskin 24.

Referring now to FIG. 4, a profile 30 of the contoured surface of thedoor skin 24 illuminated by the collimated light beam 22 is shown. Theprofile 30 of the contoured surface 26 is visible when the collimatedlight beam 22 illuminates and reflects off of the contoured surface ofthe door skin 24. The collimated light beam 22 bends in a predictablepattern based on the contours of the contoured surface of the door skin24. The raised areas of the panels 25 may be indicated or represented byinclines 32 and the depressions 26 may be indicated by or represented bydeclines 34 of the profile 30.

Referring again to FIGS. 1-3, a first sensor 40, such as a camera, maybe adapted to detect or to view the profile 30 of the contoured surfaceof the door skin 24 illuminated by the collimated light beam 22. Thecamera is positioned to receive light reflected from the contouredsurface at the area where the collimated light beam 22 impinges on thecontoured surface.

The camera 40 is positioned at a predetermined longitudinal distanceaway from the edge 27 a of the door skin 24 and at a predeterminedvertical distance above the first surface 28 a of the door skin 24. Thecamera 40 may be positioned between two and 12 feet from the firstsurface 28 a. In one embodiment, the camera 40 may be positioned five tosix feet from the first surface 28 a.

Positioning the camera 40 obliquely to the first surface 28 a of thedoor skin 24 makes the contours of the door skin 24 visible. The camera40 may be positioned relative to the first surface 28 a at an anglebetween 20 and 60 degrees. In one embodiment, the camera 40 may beplaced at an angle approximately 40 degrees above the plane of the firstsurface 28 a.

If the camera 40 were positioned perpendicular to the first surface 28 aof the door skin 24, a resulting profile (not shown) would appear as astraight line, and the contours of the door skin would be imperceptible.In addition, if the camera 40 were positioned coplanar with the firstsurface 28 a, only the highest points of the contours of the door skinlikely would be readily discernible.

The camera 40 is adapted to generate a first signal based at least inpart on the illuminated profile 30. For example, the camera 40 maycapture or record a still image of the profile 30, which may then beconverted to a digital signal. Alternatively, the camera 40 may captureor record a moving image of the profile 30.

The camera 40 may comprise a detector, which may be a Charge CoupledDevice (CCD) array, or a Complementary Metal Oxide Semiconductor (CMOS)detector array. The camera 40 may also comprise a circuit, controlelectronics, and an angled light source. In a typical CCD camera, theCCD is an analog device that is capable of holding variable charge, andtherefore is able to record varying shades of light. An analog todigital converter within the camera then quantifies the variable chargesinto discrete shades, representing the light and dark contrasts detectedby the camera.

The first signal may be a digital representation of the illuminatedprofile 30, which typically will be a lighter shade than the door skin24. The bending of the light beam 22 may be captured by the camera 40 asa pixel pattern on the CCD. The pixel pattern represents light and darkcontrasts viewed by the camera 40. The camera 40 is adapted to transmitthe first signal to the processor 50. The processor 50 is disposed inoperative communication with the camera 40. The terms “communicate” or“communication” mean to mechanically, electrically, optically, orotherwise contact, couple, or connect by either direct, indirect, oroperational means.

The processor 50 may comprise a computer-readable medium, such as arandom access memory (RAM) (not shown) coupled to a processor (notshown). The processor 50 may execute computer-executable programinstructions stored in memory (not shown). Such a processor maycomprise, for example, a microprocessor, an ASIC, or state machines.Such a processor comprises, or may be in communication with, media, forexample computer-readable media, which stores instructions that, whenexecuted by the processor, cause the processor to perform the processesdescribed herein.

Embodiments of computer-readable media include, but are not limited to,an electronic, optical, magnetic, or other storage or transmissiondevice capable of providing a processor with computer-readableinstructions. Other examples of suitable media include, but are notlimited to, a floppy disk, CD-ROM, DVD, magnetic disk, memory chip, ROM,RAM, an ASIC, a configured processor, all optical media, all magnetictape or other magnetic media, or any other medium from which a computerprocessor can read instructions.

Also, various other forms of computer-readable media may transmit orcarry instructions to a computer, including a router, private or publicnetwork, or other transmission device or channel, both wired andwireless. The instructions may comprise code from any suitablecomputer-programming language, including, for example, C, C++, C#,Visual Basic, Java, Python, Perl, and JavaScript.

The processor 50 may operate, for example, on any suitable operatingsystem capable of supporting a browser or browser-enabled application,such as Microsoft® Windows® or Linux. Such a processor includes, forexample, personal computers executing a browser application program suchas Microsoft Corporation's Internet Explorer™, Netscape CommunicationCorporation's Netscape Navigator™, and Apple Computer, Inc.'s Safari™.

The processor 50 is adapted to receive the first signal generated by thecamera 40 and to compare the first signal to a second signalrepresenting or associated with a predefined profile (not shown). Thepredefined or target profile may be selected at the outset of theprocess. The target pixel pattern may represent a surface (e.g.,contour) characteristic of the door skin 24. For example, before thedoor skin 24 enters the viewing area of the camera 40, the processor 50may be directed to compare the illuminated profile 30 with thepredefined profile.

Physical values or attributes of a door skin may be associated with apredefined profile. Such values or attributes may include, for example,pixel patterns and/or intensities, dimensions of a door skin or aposition or placement of a particular point of a profile, such as aparticular edge or side of a particular profile from a particular edgeof a door skin or from a particular position of a viewed position. Suchvalues or attributes may also include the locations from a referencepoint of rises or depressions in the contours of a door skin. Theprocessor 50 may compare a signal associated with measured attributesand respective locations of those attributes in a viewed image withattributes of a predefined profile stored in a database (not shown).

In another embodiment, the processor 50 may compare the first signal toa plurality of second signals. The plurality of second signals may eachbe associated with a plurality of predefined profiles, for exampleprofiles of a library or compilation of various patterns that may beformed in a door skin. The plurality of predefined profiles may bestored in the database in operative communication with the processor 50.

When comparing the first signal with one of a plurality of secondsignals, the processor may recognize or identify the second signal thatrepresents or is associated with a predefined profile that matchesexactly or matches closely the signal that represents or is associatedwith the illuminated profile. Where the processor 50 does not match theilluminated profile with one of the plurality of predefined profiles,the processor 50 may compare iteratively the illuminated profile withthe other predefined profiles until a match is found or until thedatabase of predefined profiles is exhausted.

The processor 50 is adapted to generate a third signal based on thecomparison of the first and second signals. The third signal maycomprise information that a value of the first signal equals a value ofone of the plurality of second signals, i.e. the third signal mayspecify which of the plurality of second signals matches the firstsignal. The third signal may also indicate that the first signal doesnot equal the value of any of the second signals. As above, the thirdsignal may also indicate that the illuminated profile is offset from thepredefined profile, or a given point or position on the predefinedprofile, by some distance.

The controller 60 is disposed in operative communication with theprocessor 50. The controller 60 may comprise, for example, aProgrammable Logic Controller. In one embodiment, the controller 60 maycomprise a relay. In another embodiment, the controller may comprise amicroprocessor. The controller 60 may comprise a processor as describedabove with reference to the processor 50. Other suitable processors maybe used. The controller 60 may be adapted to control the entire system10 or portions of the system 10, such as the conveyor 70 and/or thecutting means 90. Alternatively, the first processor 50 may be adaptedto control the system 10 without communicating to the controller 60.

The controller 60 may be adapted to receive the third signal generatedby the processor 50 and to generate a motion control signal in responseto the third signal. The motion control signal is based on the physicalvalues or attributes discussed above with reference to the predefinedprofiles. The motion control signal may be referred to as a moveinstruction, which may be absolute or incremental. The motion controlsignal may comprise an instruction to the cutting means 90 to move acertain distance to cut or trim the door skin 24.

The distance that the cutting means 90 moves may be based on the offset,or difference, between a position of a predefined (i.e., known) profileand the illuminated (e.g., viewed) profile. For example, the thirdsignal may comprise information that the illuminated profile is offsetfrom the predefined profile by some distance. Alternatively, the thirdsignal may comprise information regarding an offset of a particularreference point of the illuminated profile compared with thepredetermined profile. The motion control signal may then direct thecutting means to move that distance so that the cut is made in theappropriate location. Encoders (not shown) are used to provide feedbackon the position of the cutting means 90.

Alternatively, the motion control signal may comprise an instructionsuch that the door skin 24 is moved to another station in a productionline without being cut, or that an alert or an alarm signal iscommunicated to an interface device alerting a human operator that theilluminated profile 30 of the door skin 24 does not match any of thestored, predefined profiles.

The cutting means 90 may comprise one or more saws, knives, or splitterscontrolled by a servo-motor or other suitable cutting device. Thecutting means 90 may be adapted to be displaced relative to the doorskin 24, where the displacement of the cutting means 90 is controlled atleast in part by the motion control signal. The door skin 24 may bepre-aligned, and the cutting means 90 are adjusted relative to thepre-aligned door skin 24. Alternatively, the door skin 24 may not bepre-aligned, and the door skin 24 may be moved or displaced relative tothe cutting means 90.

The cutting means 90 is adapted to receive the motion control signal andmay be displaced or moved to cut the door skin 24. As shown in FIG. 2,the cutting means 90 has responded to the motion control signal to cutthe door skin 24 substantially aligned with the edges 29 b and 29 d.Thus, removing the material between edges 27 b and 29 b and 27 d and 29d.

In another embodiment, the system 10 may further comprise a means foraligning the door skin 24 with respect to the conveyor, oralternatively, with respect to the cutting means 90. The aligning means(not shown) may be disposed in operative communication with thecontroller 60 and may be controlled at least in part by the motioncontrol signal. The aligning means may comprise, for example, guidesthat contact the sides or the top of the door skin 24, a mechanical armthat contacts the sides or the top of the door skin 24, a portion of theconveyor 70 that contacts the bottom of the door skin 24, or any othermeans for aligning the door skin 24. The aligning means may be moveable,so as to align a door skin 24 in one of a plurality of orientations. Themotion control signal may carry a signal for the movement of thealigning means.

The system 10 may further comprise a sensor 80 in operativecommunication with the processor 50. The sensor 80 is adapted to detecta position of the door skin 24 with respect to the camera 40. The sensormay be visual, infrared, position, or any other suitable sensor. Forexample, the sensor 80 may be positioned to detect the position of thedoor skin 24 when the door skin 24 is in view of the camera 40.

The sensor 80 may communicate to the processor 50 the position of thedoor skin 24. The processor 50 may be adapted to initiate its comparisonof the first and second signals when the processor 50 receives thecommunication from the sensor 80 that the door skin 24 is in aparticular position. The sensor 80 may detect a leading edge of the doorskin 24. In another embodiment, a trailing sensor (not shown) may detecta trailing end of the door skin 24. A combination of the sensor 80 andthe trailing sensor may detect whether the door skin 24 is alignedproperly.

Referring now to FIG. 5, a method 100 according to an embodiment of thepresent invention is shown. The method 100 may be used to identify andmanipulate a door skin or other suitable objects having a contouredsurface.

As indicated by block 110, the method 100 may comprise illuminating aprofile of a contoured surface of an object, such as a door skin. Theprofile may be illuminated by emitting a collimated light beam onto thecontoured surface of the object. The profile may be illuminatedsimilarly to that described above with respect to the system 10.Alternatively, other suitable systems or methods may be used toilluminate a profile of an object.

As indicated by block 120, the method 100 may further comprise detectingthe illuminated profile of the contoured surface. As described above,the illuminated profile may be viewed by a sensor, such as a camera.Alternatively, the profile may be detected, viewed, or recorded by othersuitable sensors.

As indicated by block 130, the method 100 may further comprisetransmitting a digital representation of the illuminated profile of thecontoured surface to a processor. The processor may be similar to thatdescribed above. Alternatively, other suitable processors may be used.The camera may be adapted to generate a digital signal representing theilluminated profile detected by the camera. The sensor may be disposedin operative communication with the processor so that the digital signalgenerated by the sensor is transmitted to the processor.

As indicated by block 140, the method 100 may further comprise comparingthe illuminated profile of the contoured surface with a predefinedprofile. The profile may be compared with the predefined profile bycomparing a first signal representing or associated with the illuminatedprofile with a second signal representing or associated with thepredefined profile.

As indicated by block 150, the method 100 may further comprisemanipulating the object based at least in part on a predeterminedattribute associated with the predefined profile, for example aparticular dimension or position of the profile. As described above,manipulating the door skin may comprise repositioning the door skin,cutting the door skin, or otherwise physically altering the door skin.

A computer-readable medium of a server device, processor, or otherdevice or application comprises instructions that, when executed, causethe server device, application, processor or other device or applicationto perform method 100. The server device, resource regulatingapplication, and the computer-readable medium may be similar to thatdescribed above. Alternatively, other suitable server devices,applications, computer-readable media, processors or other devices orapplications can be used.

Referring now to FIG. 6, a method 200 according to another embodiment ofthe present invention is shown. The method 200 may be used to identifyand manipulate an object that has a contoured surface, such as a doorskin.

As indicated by block 210, the method 200 may comprise providing a lightsource adapted to emit a collimated light beam onto a contoured surfaceof an object, such as a door skin. The light source may comprise alaser. The collimated light beam may be adapted to illuminate a profileof the contoured surface by illuminating the rises and declines in thecontoured surface.

As indicated by block 220, the method 200 may further comprise providinga first sensor, such as a camera, adapted to detect the profile of thecontoured surface illuminated by the collimated light beam. The cameramay comprise a charge coupled device camera, which may view theilluminated profile of the contoured surface. The camera may be adaptedto generate a first signal based at least in part on the illuminatedprofile. For example, the camera may capture a digital image of theilluminated profile and generate a first signal associated with thatdigital image.

As indicated by block 230, the method 200 may further comprise disposinga processor in operative communication with the sensor. The processormay be adapted to receive the first signal and to compare the firstsignal with a second signal. The second signal is associated with adigital image of a predefined profile. A plurality of predefinedprofiles may be stored in a database in operative communication with theprocessor. One of the plurality of predefined profiles may be selectedfor comparison with the illuminated profile. The processor may befurther adapted to generate a third signal based on a comparison of thefirst and second signals. For example, the third signal may compriseinformation about relative or absolute positioning of the door skin, asdescribed above. The third signal may comprise other suitableinformation.

As indicated by block 240, the method 200 may further comprise disposinga controller in operative communication with the processor. Thecontroller may be similar to that described above. Alternatively, othersuitable controllers may be used. The controller may be adapted toreceive the third signal and to generate a motion control signal basedat least in part on the third signal. The motion control signal maycomprise instructions to move or manipulate the object with respect to agiven station, such as a cutting station.

As shown by block 250, the method 200 may further comprise providing aconveyor adapted to move the door skin through a plurality of stations.For example, the location at which the door skin is directly under thelight source may be one station through which the conveyor moves thedoor skin, and the location at which the cutting means cuts the doorskin may be another such station. As indicated by block 260, the method200 may further comprise providing a means for cutting the door skin,such as a saw, knife, or splitter controlled by a servo-motor, or othersuitable cutting device. The cutting means may be disposed in operativecommunication with the controller, such that the motion control signaldirects the cutting means where to cut the door skin. The conveyor mayalso be disposed in operative communication with the controller, wherethe motion control signal directs the movement of the conveyor.

As shown by block 270, the method 200 may further comprise providing ameans for aligning the door skin, either with respect to the conveyor orwith respect to the cutting means. The aligning means may be disposed inoperative communication with the controller and controlled at least inpart by the motion control signal. For example, the motion controlsignal may indicate to the aligning means that the door skin should bemoved to another position with respect to the conveyor or with respectto the cutting means. The aligning means may then move the door skinbased on the instruction of the motion control signal. The aligningmeans may comprise guides that contact the sides or the top of the doorskin, a mechanical arm that contacts the sides or the top of the doorskin, a portion of the conveyor that contacts the bottom of the doorskin, or any other suitable means for aligning the door skin.

As indicated by block 280, the method 200 may further comprise disposinga second sensor in operative communication with the processor. Thesecond sensor may be adapted to detect a position of the door skin withrespect to the camera or with respect to some other reference point. Forexample, the second sensor may be positioned to detect the position ofthe door skin when the door skin is in view of the camera. When thesecond sensor detects such a position, the second sensor may communicateto the processor the position of the door skin. The processor may beadapted to initiate the comparison of the first and second signals whenthe processor receives the communication from the second sensor that thedoor skin is in a particular position.

The foregoing description of illustrative embodiments of the inventionhas been presented only for the purpose of illustration and descriptionand is not intended to be exhaustive or to limit the invention to theprecise forms disclosed. Numerous modifications and adaptations thereofwill be apparent to those skilled in the art without departing from thespirit and scope of the present invention.

1. A system comprising: a light source adapted to emit a collimatedlight beam onto a contoured surface of an object, the collimated lightbeam adapted to illuminate a profile of the contoured surface; a firstsensor, separate from the light source, adapted to detect theilluminated profile of the contoured surface and to generate a firstsignal based at least in part on the illuminated profile; a secondsensor adapted to detect a position of the object with respect to thefirst sensor and generate a position detection signal; a processor inoperative communication with the first and second sensors, the processoradapted to receive the first signal and position detection signal and tocompare the first signal with a second signal associated with apredefined profile, wherein the processor is adapted to generate a thirdsignal based on a comparison of the first and second signals; and acontroller in operative communication with the processor, the controlleradapted to receive the third signal and to generate a motion controlsignal in response to the third signal, the motion control signal basedon an attribute of the predefined profile.
 2. The system of claim 1,wherein the processor generates the third signal when a value of thefirst signal is substantially equal to a value of the second signal. 3.The system of claim 2, further comprising: a conveyor adapted to movethe object through a plurality of stations; and a means for cutting theobject, the cutting means in operative communication with thecontroller.
 4. The system of claim 3, further comprising a means foraligning the object with respect to the conveyor, the aligning meansdisposed in operative communication with the controller and controlledat least in part by the motion control signal.
 5. The system of claim 3,further comprising a means for aligning the object with respect to thecutting means, the aligning means disposed in operative communicationwith the controller and controlled at least in part by the motioncontrol signal.
 6. The system of claim 1, wherein the attributecomprises a predetermined dimension of the predefined profile.
 7. Thesystem of claim 3, wherein the cutting means is adapted to be displacedrelative to the object, the cutting means controlled at least in partyby the motion control signal.
 8. The system of claim 1, wherein thesecond signal comprises a plurality of second signals associated with aplurality of predefined profiles.
 9. The system of claim 8, wherein theplurality of predefined profiles is stored in a database in operativecommunication with the processor.
 10. The system of claim 1, wherein theobject comprises a door skin.
 11. A method comprising: providing a lightsource adapted to emit a collimated light beam onto a contoured surfaceof an object, the collimated light beam adapted to illuminate a profileof the contoured surface; providing a first sensor, separate from thelight source, adapted to detect the profile of the contoured surfaceilluminated by the collimated light beam and adapted to generate a firstsignal based at least in part on the illuminated profile; providing asecond sensor adapted to detect a position of the object with respect tothe first sensor and generate a position detection signal; disposing aprocessor in operative communication with the first and second sensors,the processor adapted to receive the first signal and position detectionsignal and to compare the first signal with a second signal associatedwith a predefined profile, wherein the processor is adapted to generatea third signal based on a comparison of the first and second signals;and disposing a controller in operative communication with theprocessor, the controller adapted to receive the third signal and togenerate a motion control signal in response to the third signal, themotion control signal based on an attribute of the predefined profile.12. The method of claim 11, wherein the processor generates the thirdsignal when a value of the first signal is substantially equal to avalue of the second signal.
 13. The method of claim 11, furthercomprising: providing a conveyor adapted to move the object through aplurality of stations; and providing a means for cutting the object, thecutting means in operative communication with the controller.
 14. Themethod of claim 13, further comprising providing a means for aligningthe object with respect to the conveyor, the aligning means disposed inoperative communication with the controller and controlled at least inpart by the motion control signal.
 15. The method of claim 13, furthercomprising providing a means for aligning the object with respect to thecutting means, the aligning means disposed in operative communicationwith the controller and controlled at least in party by the motioncontrol signal.
 16. The method of claim 11, wherein the attributecomprises a predetermined dimension of the predefined profile.
 17. Themethod of claim 11, wherein the second signal comprises a plurality ofsecond signals associated with a plurality of predefined profiles. 18.The method of claim 11, wherein the object comprises a door skin.